AuRACLE CRM Cylinder Twin Engine Management System Installation Manual - 1 -

Transcription

1 AuRACLE CRM Cylinder Twin Engine Management System Installation Manual - 1 -

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3 Table of Contents 1 Important Installation/Warranty Information About the AuRACLE Installation Manual Notes Warnings and Cautions Important Pre-Installation Information Product Introduction System Specifications Power Input Requirements Function Approval Definitions DU Environmental Classifications EIU Environmental Classifications FQU Environmental Classifications System Safety Considerations Functional Hazard Analysis System Safety Assessment Installation Kit Contents Base System Definitions AuRACLE CRM 2120 Horizontal (Narrow) 6-Cylinder Base System System Labels Sensors Twin 6-Cyl Base Sensor Set ( ) Parts List for EGT Sensor (12 Req.) Parts List for CHT Sensor (12 Req.) Parts List for Oil Temp Sensor (2 Req.) Parts List for OAT Sensor (1 Req.) Parts List for Oil Pressure Sensor (2 Req.) Parts List for Manifold Pressure Sensor (2 Req.) Parts List for Fuel Flow Sensor (2 Req.) Parts List for Current Shunt (3 Req.) Tachometer Option Sensors Parts List for Tachometer Sensor (2 Req.) Parts List for Tachometer Sensor (2 Req.) Pneumatic Instrument Power Option Sensors Parts List for Instrument Pressure Sensor (1 Req.) Parts List for Suction Sensor (1 Req.) Carburetor Temperature Option Sensors Parts List for CT Sensor (2 Req.) Fuel Pressure Option Sensors Parts List for Fuel Pressure Sensor (35 PSIG) (2 Req.) Parts List for Fuel Pressure Sensor (70 PSIG) (2 Req.) Parts List for Diff Fuel Pressure Sensor (35 PSIG) (2 Req.) Turbo Option Sensors Parts List for TIT Sensor (2 Req.) Parts List for IAT Sensor (2 Req.)

4 6.2.7 Intercooler Option Sensors Parts List for CDT Sensor (2 Req.) CHT Ring Sensor Option Parts List for CHT Sensor (12 Req.) Mounting Hardware ( ) DU Mounting Hardware EIU Mounting Hardware Fuel Quantity Unit Mounting Hardware Documentation Installation Instructions Display Unit (DU) Installation Choose the Proper Installation Location Remove or Relocate Any Interfering Systems Cut-out DU Installation Holes DU Control Panel Installation DU Connector Definitions Network Interface Cables Determine the Firewall Mounting Hole Position Connect the Network Cables Connect the Cockpit Cable Install Cockpit Cable Connect the Power Connect to the Lighting Bus Connect the OAT Sensor Connect Alarm Connect GPS Post Light Requirement Fuel Quantity Unit (FQU) Installation Install FQU to CO and AMPS Cable Connect CO Detector Engine Interface Unit (EIU) Installation Attach the 6-Cyl Electronics Enclosure Install the Network Cables Terminate Network Cables Sensor Installation EIU Sensor Interface Cable J EIU Sensor Interface Cable J Sensor Wiring General Recommendations Thermocouple Wiring General Recommendations Pressure Sensor Mounting General Recommendations Install EGT Sensor Install CHT Sensors Install TIT Sensor(s) (if req.) Carburetor Temperature Sensor (if req.) Install Induction Temperature Sensor (if req.)

5 Install Compressor Discharge Temperature Sensor (if req.) Install Oil Temperature Sensor Install Oil Pressure Sensor Install Manifold Absolute Pressure (MAP) Sensor Install Instrument Air Pressure/Vacuum Sensor Install Fuel Pressure Sensor Install RPM Sensor Solid-State Magneto Pick-up (Slick or Bendix Magnetos) Install Current Shunts Install Fuel Flow Sensor Compute the Total Weight and Moment Changes Load Operational Parameters Calibrate Fuel Level Aircraft Configuration Verification Operation Verification Instructions for Continued Airworthiness (ICA) Pressurized Aircraft Penetration Location Installation Testing Installer Comments Change History

6 1 Important Installation/Warranty Information PLEASE READ THE LIMITED WARRANTY / AGREEMENT. There is information in the Limited Warranty / Agreement that may alter your decision to install and utilize this product. IF YOU DO NOT ACCEPT THE TERMS OF THE LIMITED WARRANTY/ AGREEMENT DO NOT INSTALL AND UTILIZE THE PRODUCT. WARRANTY DEFINITIONS LIABILITY - IT IS AN EXPRESS CONDITION OF SALE THAT LIABILITY IS LIMITED TO THE COST OF THE GOODS PROVED TO BE DEFECTIVE. UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE LIABLE TO THE CUSTOMER OR TO THIRD-PARTIES FOR LOSS (INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFIT OR DATA), DAMAGE OR INJURY HOWSOEVER ARISING. THE CUSTOMER SHALL INDEMNIFY THE COMPANY IN RESPECT TO ALL DAMAGE OR INJURY OCCURRING TO ANY PERSONAL PROPERTY AND AGAINST ANY ACTIONS AND EXPENSES IN THAT CONNECTION FOR WHICH THE COMPANY MAY BECOME LIABLE IN RESPECT OF THE GOODS SOLD IF THE DAMAGE OR INJURY IS CAUSED BY NEGLIGENCE OF THE CUSTOMER OR HIS SERVANTS OR AGENTS. WARRANTIES - THE COMPANY OFFERS THE CUSTOMER THE BENEFIT OF THE WARRANTY PERIOD AS SHOWN BELOW. NO ADDITIONAL WARRANTIES ARE OFFERED. WARRANTY POLICY ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS, WARRANTS ALL MANUFACTURED HARDWARE TO BE FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF THREE (3) YEARS FROM THE DATE OF SHIPMENT. ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS, WARRANTS ALL SUPPLIED SENSORS AND SENDERS TO BE FREE FROM DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD DEFINED BY THE INDIVIDUAL SENSOR MANUFACTURER FROM THE DATE OFSHIPMENT. THIS WARRANTY COVERS REPAIR AND/OR REPLACEMENT, AT OUR OPTION, OF ANY PARTS FOUND TO BE DEFECTIVE, PROVIDED SUCH DEFECTS, IN OUR OPINION ARE DUE TO FAULTY MATERIAL OR WORKMANSHIP AND ARE NOT CAUSED BY TAMPERING OR ABUSE. THE WARRANTY DOES NOT INCLUDE CHARGES FOR REMOVAL, SHIPPING AND REINSTALLATION. ALL WARRANTIES ARE F.O.B. ULTRA ELECTRONICS FLIGHTLINE SYSTEMS 7625 OMNITECH PLACE VICTOR, NY (800) ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS WILL NOT ACCEPT OR PAY FOR ANY CHARGES FOR WARRANTY WORK PERFORMED OUTSIDE OUR FACTORY WITHOUT PRIOR WRITTEN CONSENT

7 THIS WARRANTY APPLIES ONLY TO PRODUCTS IN NORMAL USE. IT DOES NOT APPLY TO UNITS OR CIRCUIT BOARDS DEFECTIVE DUE TO IMPROPER INSTALLATION, PHYSICAL DAMAGE, TAMPERING, LIGHTNING OR OTHER ELECTRICAL DISCHARGE, UNITS WITH ALTERED SERIAL NUMBERS, OR UNITS REPAIRED BY UNAUTHORIZED PERSONS OR IN VIOLATION OF ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS INSTALLATION PROCEDURES. ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS WARRANTS NO PART OF THE INSTALLATION NOR THE ASSOCIATED COSTS ASSOCIATED WITH THE INSTALLATION. ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS, ASSUMES NO RESPONSIBILITY FOR ANY CONSEQUENTIAL LOSSES OF ANY NATURE WITH RESPECT TO ANY PRODUCTS OR SERVICES SOLD, RENDERED, OR DELIVERED. THE FOREGOING ARE THE ONLY HARDWARE WARRANTIES FOR THE AuRACLE CRM 2100 SYSTEM, EXPRESSED OR IMPLIED. NO OTHER HARDWARE WARRANTIES EXIST. THE FOREGOING PARAGRAPHS DEFINE AND LIMIT ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS SOLE RESPONSIBILTY AND LIABILITY AND PURCHASER S SOLE AND EXCLUSIVE REMEDIES RELATED TO THE PRODUCT. FOR FACTORY ASSISTANCE, PLEASE FEEL FREE TO CALL OUR CUSTOMER SERVICE DEPARTMENT FOR ASSISTANCE IN SERVICE OR INSTALLATION. CALL (585) BETWEEN 9:00 AM AND 5:00 PM EASTERN TIME, MONDAY THROUGH FRIDAY. WE DO NOT ACCEPT COLLECT CALLS. PLEASE HAVE THE SERIAL NUMBER OF THE UNIT AVAILABLE WHEN YOU CALL, ALONG WITH AS MANY DETAILS OF THE NATURE OF THE PROBLEM AS POSSIBLE. IF YOU PREFER, YOU MAY ALSO FAX US AT (585) HOURS A DAY. WE WILL RESPOND BY FAX OR TELEPHONE WITHIN ONE BUSINESS DAY OF RECEIVING YOUR FAX. REPAIR OF THE ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS AuRACLE CRM 2100 SYSTEM IS PERFORMED AT THE FACTORY. FACTORY SERVICE INCLUDES A COMPLETE CHECKOUT AND RECALIBRATION. THE ONLY COSTS FOR FACTORY REPAIR OF A UNIT STILL UNDER WARRANTY ARE THE SHIPPING CHARGES, UNIT REMOVAL, AND RE-INSTALLATION. PRIOR TO RETURNING A UNIT FOR SERVICE, GO TO THE ULTRA ELECTRONICS FLIGHTLINE SYSTEMS WEBSITE ( TO COMPLETE AN RMA REQUEST FORM. YOU WILL BE CONTACTED WITH AN RMA NUMBER. PLEASE NOTE THAT ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS WILL NOT ACCEPT A UNIT RETURNED TO THE FACTORY WITHOUT AN RMA NUMBER. SECURELY PACK THE UNIT IN A SECURE SHIPPING CARTON, WRITE THE RMA NUMBER ON THE OUTSIDE OF THE CARTON, AND RETURN IT TO THE ADDRESS SHOWN IN ABOVE. INCLUDE YOUR NAME, COMPLETE SHIPPING ADDRESS AND DAYTIME TELEPHONE NUMBER, A COMPLETE DESCRIPTION OF THE PROBLEM, AND THE DESIRED RETURN DATE AND SHIPPING METHOD. IF A SUITABLE FOAM-PACKED CARTON IS NOT AVAILABLE, CONTACT ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS TO ARRANGE FOR PACKAGING MATERIALS. ULTRA ELECTRONICS - FLIGHTLINE SYSTEMS, WILL NOT BE RESPONSIBLE FOR DAMAGE WHICH OCCURS DUE TO POORLY PACKAGED RETURNS

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9 2 About the AuRACLE Installation Manual 2.1 Notes Warnings and Cautions Notes and warnings provide guidance for the use of the AuRACLE. For your own safety, Ultra Electronics - Flightline Systems strongly suggests that you pay close attention to notes and warnings. Note: Notes provide useful information about how to use the AuRACLE. CAUTION: Cautions denote information that can affect the operation of the system in an adverse way. WARNING: Warnings denote information that will affect the operation of the system in an adverse way and possibly cause damage to the instrument, erroneous readings, or unsafe conditions. 2.2 Important Pre-Installation Information It is possible for any instrument to fail and display inaccurate readings. The ability of this product to detect and display a problem is directly related to proper programming by an approved installer as well as the pilot s interpretation and observation skills. Before starting the installation, make sure that you planned installation will not interfere with the operating of any controls. The installer should use current aircraft standards and practices to install this produce. Refer to the following Advisory Circulars: AC B Inspection and Repair Techniques AC B Alteration Techniques To Whom It May Concern: Ultra Electronics Flightline Systems, Holder of STC XXXXXXXNY: grants to the purchaser, of an AuRACLE Engine Management System covered by this Installation Manual, permission to install said system under the above STC. WARNING: This system may only be installed in Part 23 piston engine aircraft CAUTION: A copy of the AuRACLE Engine Management System Airplane Flight Manual Supplement to the aircraft Pilots Operating Handbook must be kept in the aircraft at all times

10 Note: All graphics contained within this document, including screenshots and other displays, are for reference use only and are subject to change. The graphics contained herein may differ slightly from your actual equipment or display. WARNING: This manual assumes that the reader is an appropriately licensed and authorized installation technician. If you have questions regarding the installation of this system, please contact Ultra Electronics Flightline Systems at , prior to installing this product. WARNING: The aircraft battery MUST be disconnected during the installation of the AuRACLE Engine Management System. Any damage that occurs as a result of not disconnecting the battery during installation will NOT be covered by the product Warranty. WARNING: When wiring connections and securing the cable, be sure wiring does not obstruct the aircraft control movement under the instrument panel. This may present a safety hazard and will void your warranty

11 3 Product Introduction The AuRACLE Engine Management System provides a graphical representation of all engine instrumentation as well as the precise multi-cylinder engine monitoring of Exhaust Gas Temperature (EGT) and Cylinder Head Temperature (CHT). The AuRACLE is designed to act as the PRIMARY engine instrumentation for your aircraft. The unit SHALL be configured properly to reflect OEM instrumentation scales, exceedance limitations, and warnings. Once configured to your respective airframe and engine combination, the AuRACLE will provide you with the most advanced monitoring available. The AuRACLE is intended to provide primary replacement for the following functions in piston engine aircraft. Manifold Pressure RPM Fuel Flow Exhaust Gas Temperature Turbine Inlet Temperature Cylinder Head Temperature Oil Pressure Oil Temperature Induction Air Temperature Compressor Discharge Temperature Fuel Pressure Fuel Quantity Outside Air Temperature Amps Volts CO Level Tachometer Time Percent Horsepower Actual Horsepower Fuel Computer

12 Note: Consult the original Pilot s Operating Handbook (POH) provided with the aircraft and/or sensors prior to operation. The POH contains information specific to your aircraft and will contain operating limitations applicable to your aircraft. The AuRACLE has been programmed to meet the limits and exceedance requirements matching your original engine instruments. Your STC specific Instrument Marking Report should be referenced. On power up, the system performs a brief hardware self-test. After the system initializes (about a minute after power-on), the Ultra Electronics splash page at which point the fuel entry screen is displayed along with the primary instrument page. WARNING: During the power up and screen self-tests, the system will display Wait for data prior to starting the engine. It is strongly recommended that the pilot wait until the hardware and software self-tests are completed prior to engine start

13 Figure 1: Typical System Overview (actual systems may vary)

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15 4 System Specifications The conditions and tests required for TSO approval of this article are minimum performance standards. It is the responsibility of those installing this article either on or within a specific type or class of aircraft to determine that the aircraft installation conditions are within TSO standards. TSO articles must have separate approval for installation in an aircraft. The article may be installed only if performed under 14 CFR Part 43 or the applicable airworthiness requirements 4.1 Power Input Requirements The AuRACLE CRM 2120 System will operate without modification in either 12V or 24V electrical systems. The worst case power draw of the system is 2.5A (during cold cranking) 4.2 Function Approval Definitions Parameter TSO Class Range EGT TSO-C43c IIa o F CHT TSO-C43c IIa o F TIT TSO-C43c IIa o F Oil T TSO-C43c IIIa +/-300 o F OAT TSO-C43c IIIa +/-100 o C IAT TSO-C43c IIIa +/-200 o F CDT TSO-C43c IIIa +/-300 o F CT TSO-C43c IIIa +/-200 o F Fuel Flow TSO-C44c N/A 0 60 GPH MAP TSO-C45b N/A 0 60 in-hg Oil P TSO-C47 N/A PSIG IP TSO-C47 N/A 0 20 in-hg FP TSO-C47 N/A 0 35 PSIG RPM TSO-C49b N/A RPM Display TSO-C113 N/A N/A Fuel Quantity TSO-C55a I/II N/A Amps N/A N/A +/- 75 Amps Volts N/A N/A 0 40 Volts Horsepower N/A N/A HP % Horsepower N/A N/A 0-120% Fuel Computer - Load N/A N/A Gal Tach Time N/A N/A 0 10,000 Hrs CO Display N/A N/A

16 4.3 DU Environmental Classifications DO-160F Test (Section) Category Comments Temp. & Alt. (4) C1 Storage Temp High: +85C Short Term High Temp: +70C Op High Temp +55C Op Low Temp: -20C Short Term Low Temp -40C Storage Temp Low: -55C Loss of Cooling Altitude Temp Variation (5) C 2C/min Humidity (6) A Op-Shock & Crash (7) B Vibration (8) S, Curve M Explosive Atmosphere X (9) Waterproofness (10) X Fluids Susceptibility (11) X Sand & Dust (12) X Fungus Resistance (13) F Salt Spray (14) X Magnetic Effect (15) Z Power Input (16) BXX Voltage Spike (17) B Audio Freq Cond B Suscept Pwr In (18) Induced Sig AC Susceptibility (19) RF Susceptibility (20) TT RF Emission (21) L Lightning Induced Trans A2C22 (22) Lightning Direct Effects X (23) Icing (24) X ESD (25) A Flammability (26) C NA 35,000 ft

17 4.4 EIU Environmental Classifications DO-160F Test (Section) Category Comments Temp. & Alt. (4) C3 Storage Temp High: +125C Short Term High Temp: +125C Op High Temp +100C Op Low Temp: -45C Short Term Low Temp -55C Storage Temp Low: -55C Loss of Cooling Altitude Temp Variation (5) A 10C/min Humidity (6) C Op-Shock & Crash (7) A Vibration (8) S, Curve L Explosive Atmosphere H (9) Waterproofness (10) W Fluids Susceptibility (11) F Sand & Dust (12) D Fungus Resistance (13) F Salt Spray (14) X Magnetic Effect (15) Z Power Input (16) BXX Voltage Spike (17) B Audio Freq Cond B Suscept Pwr In (18) Induced Sig AC Susceptibility (19) RF Susceptibility (20) TT RF Emission (21) L Lightning Induced Trans A2C22 (22) Lightning Direct Effects X (23) Icing (24) A ESD (25) A Flammability (26) C NA 35,000 ft

18 4.5 FQU Environmental Classifications DO-160F Test (Section) Category Comments Temp. & Alt. (4) C1 Storage Temp High: +85C Short Term High Temp: +70C Op High Temp +55C Op Low Temp: -20C Short Term Low Temp -40C Storage Temp Low: -55C Loss of Cooling Altitude Temp Variation (5) C 2C/min Humidity (6) A Op-Shock & Crash (7) B Vibration (8) S, Curve M Explosive Atmosphere X (9) Waterproofness (10) X Fluids Susceptibility (11) X Sand & Dust (12) X Fungus Resistance (13) F Salt Spray (14) X Magnetic Effect (15) Z Power Input (16) BXX Voltage Spike (17) B Audio Freq Cond B Suscept Pwr In (18) Induced Sig AC Susceptibility (19) RF Susceptibility (20) TT RF Emission (21) L Lightning Induced Trans A2C22 (22) Lightning Direct Effects X (23) Icing (24) X ESD (25) A Flammability (26) C NA 35,000 ft

19 5 System Safety Considerations 5.1 Functional Hazard Analysis The following Functional Hazard Assessment is based on the guidelines presented in AC D, figure 2 and Appendix A. Ultra believes that within these limitations there is no difference in the Classification of Failure Conditions between Class I and Class IV airplanes. The allocation of failure probabilities in the Failure Modes and Effects Analysis will differ between the classes but, the system level probabilities will not differ among classes. Classification of Failure Condition Quantitative Probability All Classes Software Assurance Level Hazard Total Loss of displayed Information Major <10-5 C Total Loss of CHT Information Minor <10-3 D Display of misleading CHT Information Minor <10-3 D Loss of 1 CHT channel s Information Minor <10-3 D Display of misleading 1 channel of CHT Minor <10-3 D Information Total Loss of EGT Information Minor <10-3 D Display of misleading EGT Information Minor <10-3 D Loss of 1 EGT channel s Information Minor <10-3 D Display of misleading 1 channel of EGT Minor <10-3 D Information Total Loss of Oil Pressure Information Minor <10-3 D Display of misleading Oil Pressure Information Minor <10-3 D Total Loss of Oil Pressure Information Minor <10-3 D Display of misleading Oil Pressure Information Minor <10-3 D Total Loss of Oil Temperature Information Minor <10-3 D Display of misleading Oil Temperature Information Minor <10-3 D Total Loss of CDT Information Minor <10-3 D Display of misleading CDT Information Minor <10-3 D Total Loss of RPM Information Minor <10-3 D Display of misleading RPM Information Minor <10-3 D Total Loss of MAP Information Minor <10-3 D Display of misleading MAP Information Minor <10-3 D Total Loss of TIT Information Minor 1 <10-3 D Display of misleading TIT Information Major 1 <10-5 C Total Loss of FF Information Minor <10-3 D Display of misleading FF Information Major <10-5 C Total Loss of FP Information Minor <10-3 D Display of misleading FP Information Minor <10-3 D

20 Classification Quantitative of Failure Probability Hazard Condition All Classes Software Assurance Level Total Loss of FL/FQ Information Minor <10-3 D Display of misleading FL/FQ Information Minor <10-3 D Total Loss of OAT Information Minor <10-3 D Display of misleading OAT Information Minor <10-3 D Total Loss of WT Information Minor <10-3 D Display of misleading WT Information Minor <10-3 D Total Loss of CT/IAT Information Minor 1 <10-3 D Display of misleading CT/IAT Information Minor 1 <10-3 D Total Loss of VAC/IP Information Minor <10-3 D Display of misleading VAC/IP Information Major <10-5 C Total Loss of AMP Information Minor <10-3 D Display of misleading AMP Information Major <10-5 C Total Loss of VLT Information Minor <10-3 D Display of misleading VLT Information Major <10-5 C Total Loss of Computed Fuel Management Data Minor <10-3 D Display of misleading Computed Fuel Minor <10-3 D Management Data Total Loss of the Leaning functions Minor 1 <10-3 D Display of misleading Leaning data Minor 1 <10-3 D Total Loss of the Horsepower functions Minor 1 <10-3 D Display of misleading Horsepower data Minor 1 <10-3 D Total Loss of Carbon Monoxide Indication Minor 1 <10-3 D Display of misleading Carbon Monoxide Indication Minor 1 <10-3 D Total Loss of the Pitot Pressure Minor 1 <10-3 D Display of misleading Pitot Pressure Minor 1 <10-3 D Total Loss of the Static Pressure Minor 1 <10-3 D Display of misleading Static Pressure Minor 1 <10-3 D Total Loss of the Longitudinal Acceleration Minor 1 <10-3 D Display of misleading Longitudinal Acceleration Minor 1 <10-3 D Total Loss of the Lateral Acceleration Minor 1 <10-3 D Display of misleading Lateral Acceleration Minor 1 <10-3 D Total Loss of the Vertical Acceleration Minor 1 <10-3 D Display of misleading Vertical Acceleration Minor 1 <10-3 D Total Loss of the Lighting Bus Level Minor 1 <10-3 D Display of misleading Minor 1 <10-3 D Total Loss of the USB Functions No Effect 1 N/A E Storage of misleading USB Data No Effect 1 N/A E 1 indicates item is not from AC D, they result from Ultra Electronics - Flightline Systems Analysis

21 5.2 System Safety Assessment The table above provides calculated probabilities of the occurrence of Functional Hazards (last column). Sensor Reliabilities estimated as: Pressure Sensors 5 x 10-8 (50.7 FITS) Low Temperature Thermocouples 1 x 10-6 High Temperature Thermocouples 1 x 10-5 Current Shunt 1 x 10-8 RPM Sensor 1 x 10-7 FF Sensor 1 x

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23 6 Installation Kit Contents The following describes the parts of the AuRACLE system for installation into this aircraft. 6.1 Base System Definitions AuRACLE CRM 2120 Horizontal (Narrow) 6-Cylinder Base System The system components are defined in XA SCI as Part # TAB-1. These items are covered by the Ultra Electronics - Flightline Systems TSO of this system. This consists of: NARROW HORIZONTAL TWIN 6-CYL MOUNTING SET HORIZONTAL TWIN ASSEMBLY, NARROW CONTROL PANEL ASSEMBLY FOR TWIN HORIZONTAL TWIN SUB-ASSEMBLY, NARROW CONTROL PANEL CABLE ASSEMBLY 18IN TAB-4 AURACLE II 6-CYL EIU ASSEMBLY. RIGHT-ANGLE CONNECT FUEL QUANTITY ASSEMBLY TAB-1 FQU TO FUEL TANK CABLE ASSEMBLY 15FT TAB-2 FQU TO CO AND AMPS CABLE ASSEMBLY 20FT TAB-1 FQU TO DU CABLE ASSEMBLY 20FT TAB-1 DU TO EIU CABLE ASSEMBLY 20FT TAB-1 FQU TO EIU CABLE ASSEMBLY 20FT TAB-1 COCKPIT CABLE ASSEMBLY FOR TWIN 10FT TAB-4 J1-1 CABLE ASSEMBLY 10 FT TAB-4 J1-2 CABLE ASSEMBLY TYPE J CHT 10 FT USB FLASH DRIVE USB DUST CAP

24 System Labels The following are examples of the system labels:

25 6.2 Sensors Note: not all sensors are included in all installations. The following lists include typical sensors. To determine the exact contents of any particular installation see the system packing list Twin 6-Cyl Base Sensor Set ( ) Parts List for EGT Sensor (12 Req.) (1) EGT/IAT/CDT Thermocouple P/N (2) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Parts List for CHT Sensor (12 Req.) (1) Threaded CHT Sensor P/N (2) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Parts List for Oil Temp Sensor (2 Req.) (1) OT Sensor P/N (4) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Parts List for OAT Sensor (1 Req.) (1) OAT Sensor P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N (4) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N

26 Parts List for Oil Pressure Sensor (2 Req.) (1) Oil Pressure Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Manifold Pressure Sensor (2 Req.) (1) Manifold Pressure Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Flow Sensor (2 Req.) (1) Fuel Flow Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Current Shunt (3 Req.) (1) Current Shunt P/N P/N MS (2) Ring Terminals P/N (2) Screws 8-32 X 1 P/N (2) 8-32 Nyloc Nuts P/N (2) #8 Flat Washers P/N MS Tachometer Option Sensors Note: One or the other of the following sensor sets will be included in the sensor kit Parts List for Tachometer Sensor (2 Req.) (1) RPM Hall Effect Sensor (Bendix Mag.) P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N (1) Tachometer Cable Cap P/N Parts List for Tachometer Sensor (2 Req.) (1) RPM Hall Effect Sensor (Slick Mag.) P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N (1) Tachometer Cable Cap P/N

27 6.2.3 Pneumatic Instrument Power Option Sensors Note: One or the other of the following sensor sets will be included in the sensor kit Parts List for Instrument Pressure Sensor (1 Req.) (1) Instrument Pressure Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Suction Sensor (1 Req.) (1) Suction Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Carburetor Temperature Option Sensors Parts List for CT Sensor (2 Req.) (1) CT Sensor P/N (4) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Fuel Pressure Option Sensors Parts List for Fuel Pressure Sensor (35 PSIG) (2 Req.) (1) Fuel Pressure Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Fuel Pressure Sensor (70 PSIG) (2 Req.) (1) Fuel Pressure Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N

28 (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Parts List for Diff Fuel Pressure Sensor (35 PSIG) (2 Req.) (1) Fuel Pressure Sensor P/N (3) Butt Splices P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Note: Sensor mounting hardware and pressure fittings Installer Supplied Turbo Option Sensors Parts List for TIT Sensor (2 Req.) (1) EGT Sensor (Protective Sleeve & Tie Wraps) P/N (2) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N Parts List for IAT Sensor (2 Req.) (1) EGT/IAT/CDT Thermocouple P/N (2) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N Intercooler Option Sensors Parts List for CDT Sensor (2 Req.) (1) EGT/IAT/CDT Thermocouple P/N (2) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N (1) Protective Sleeve P/N (3) Tie Wraps P/N CHT Ring Sensor Option Note: May be used in place of if required by space constraints. An installation must contain ALL or ALL These sensors may not be mixed on an aircraft

29 Parts List for CHT Sensor (12 Req.) (1) Ring CHT Sensor (Protective Sleeve & Tie Wraps) P/N (2) Ring Terminals P/N (2) Screws 6-32 X 3/16 P/N (2) 6-32 Nuts P/N (2) #6 Star Washers P/N Mounting Hardware ( ) DU Mounting Hardware (1) Installation Template P/N (1) DU Mounting Bracket, Narrow P/N (1) Control Panel for Horiz Twin Mtg Bracket P/N (4) 8-32 X 3/4 SHCS, SS, BLKOX P/N (4) 4-40 X 5/16 FHCS, BLKOX P/N (4) 4-40 X 3/8, SHCS, SS, BLKOX P/N EIU Mounting Hardware (8) EIU Mounting Spacers P/N (8) 8-32 X 1 Pan Head Machine Screws P/N (8) 8-32 Nyloc Nuts P/N (8) #8 Flat Washers P/N MS (2) Pressure Transducer Mounting Bracket P/N Fuel Quantity Unit Mounting Hardware (4) #6-32 X ¾ FLH, 82 Deg, SS, Blkox P/N (4) #4-40 X 3/8, SHCS, SS, Blkox P/N Documentation (1) AuRACLE Twin Pilot s Guide P/N (1) AuRACLE Twin AFMS P/N (1) AuRACLE Twin Narrow Horizontal 6-Cyl Install Guide P/N (1) EGView Analysis Software P/N

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31 7 Installation Instructions 7.1 Display Unit (DU) Installation Choose the Proper Installation Location The DU is best located within the natural scan and easy reach of the pilot. The recommended mounting location is defined as an imaginary box defined with respect to the Primary Flight Instrument T and the control wheel axle. The recommended optimal mounting location is within a box (see Figure 2: Suggested AuRACLE Mounting Area) as defined below: HORIZONTAL ORIENTATION: The centerline of the AuRACLE LCD display may be mounted from the left side of the Instrument panel to a maximum of 21 to the right of the vertical centerline (Control Wheel center of rotation). The idea is mount the centerline of the AuRACLE LCD display no more than 21 to the right of the Pilot s centerline; so that the Pilot may easily read and interact with the AuRACLE. VERTICAL ORIENTATION: The AuRACLE may be mounted within +/- 7 from the horizontal centerline of the Primary Flight Instrument T. The installer should insure that the AuRACLE display is not obstructed by either the glare shield or the control wheel. Note: Any installation that requires that the AuRACLE be mounted outside of the Box will require FAA involvement for installation approval

32 Figure 2: Suggested AuRACLE Mounting Area Remove or Relocate Any Interfering Systems The following is a picture of a typical instrument panel prior to installation. Figure 3: Typical Panel Prior To Installation

33 1. Remove the Instruments in the chosen installation area that are replaced by the AuRACLE (For the example shown above: Manifold Pressure, Tachometer, Fuel Flow, and EGT. For a list of possible replacements see section 4.2).This will provide most, if not all, of the space required to install the AuRACLE. Remove or relocate other instruments that will interfere with the following steps. This location is for reference only. The installing A&P and IA should decide that where the installation is to occur does not conflict with the viewing angle suggestions listed above and is consistent with all applicable Advisory Circulars. Note: Any appliances that are installed under the original Type Certificate (TC) that requires relocation should be relocated in accordance with the guidance provided in AC B, Section 15.4 (presented below). Special care should be exercised to insure that proper pilot visibility of displays and pilot access to controls in not interfered with, with respect to relocated instruments and non-relocated instruments. Note: Any appliances that are installed under a Supplemental Type Certificate (STC) that requires relocation should be relocated in accordance with the original STC installation instructions or in accordance with the guidance provided in AC B, Section 15.4 (presented below). Special care should be exercised to insure that proper pilot visibility of displays and pilot access to controls in not interfered with, with respect to relocated instruments and non-relocated instruments. Excerpt from AC B 15.4 Recommended Location for Displaying Information Table 1 contains the recommended location for displaying information intended for new panel layout with integrated electronic displays; however, these guidelines should be followed for other installations as practicable. Deviations beyond these limits may be approved for individual flight instruments depending on the combination of factors listed in section These deviations need a display installation evaluation. It may not be practicable for retrofit installations with new electronic displays, such as with ATC, STC, and field approvals, to comply with the values in the table. This is due to limitations in the systems and incompatible technologies between the aircraft and the system being added. In such cases, for any given item, the angular deviations should not increase from what was originally found to be acceptable, and the display characteristics should be at least as good as the original display. For retrofit installations, it may be acceptable for installations to fall outside the recommended data in Table 1. These deviations may need an evaluation by the certification authority. Factors to consider during this evaluation include the distinguish ability, attention-getting quality, readability, etc. The field-of-view angles should be applied for installation approvals where a design eye reference point exists. For installation approvals where no design eye reference point is defined, the linear panel distances from center in Table 1 should be used

34 Data Recommended Field-of-View FOV, Deg from Pilot View Centerline (NOTE 1) Approx. Distance(inches) From Reference Center Line (NOTE 1) PFI Basic T Electronic or 4 (NOTE 2) 2 (NOTE 2) Mechanical Navigation Course Error Data (HSI, 15 8 CDI, FD) Autopilot and /Flight Director Modes 15 8 Navigation Source Annunciation 15 (NOTE 3) 8 (NOTE 3) System Warnings and Cautions- 15 (NOTE 4) 8 (NOTE 4) Including failure annunciation Required Powerplant Advisories Annunciations Standby Instruments 35 (NOTE 5) 21 (NOTE 5) Reversionary Display for PFI Electronic Map Display that is not used to replace the CDI/HSI/FD 35 (NOTE 6) 21 (NOTE 6) NOTE 1. The FOV angles and Approximate Distance from Center Reference Line, based on a viewing distance of 30 inches from the panel, are defined as acceptable angles and distance to each data source from the center of basic T, or pilot view centerline. Distances are measured center-to-center of the display in question, measured horizontally. Vertical placement in the panel can be from just below the basic T to the glare shield. NOTE 2. Display PFI as close to the center of reference as possible. NOTE 3. The navigation source annunciation should be on or near the affected display and should appear on the same side of the basic T as the affected display. The guidelines for the proximity to the affected display depend on the size, color, and distinguishing characteristics of the source annunciation. NOTE 4. Warnings and cautions can be presented within 35 degrees if they are associated with a unique aural tone or a master warning/caution light that is within 15 degrees. The warnings and cautions should be in a consistent location, such as on an annunciator panel. If an aural tone is used, it should be readily distinguishable from all other cockpit sounds and provide unambiguous information to direct the pilot s attention to a visual indication of the condition. Consider the number of aural alerts. NOTE 5. Install the standby instruments as close as practicable to the PFI Cut-out DU Installation Holes If the panel has too many holes for a clean installation, it is recommended that an Aluminum overlay panel be constructed and installed (4 to screws) over the original instrument panel and the AuRACLE DU be installed into this overlay panel. The photo below shows a typical overlay panel type installation

35 Figure 4: Overlay Panel Type Installation 1. Once the general site for the AuRACLE DU is determined, a small hole is drilled in the instrument panel in the approximate center of the large hole in the template. A screw and fender washer is then used to hold the template, through hole E, in place against the instrument panel. 2. It is now possible to fine tune the position of the template. Once the final position is determined tighten the mounting screw to firmly secure the installation template. 3. Using the template holes as a guide, drill all ten (10) holes C, D, and F using the respective specified sized drill 4. Connect the holes D with straight-lines and cut-out the mounting hole accordingly. File as required. 5. Countersink the two 4-40 mounting bracket holes F then install the DU Mounting Bracket ( ) directly behind the panel utilizing the 4-40 mounting holes in the top and the bottom of the bracket

36 6. Install the DU in the Instrument panel inserting the using the four supplied 8-32 Socket Head Cap Screws ( ) through the panel and the into DU Mounting Bracket

37 Figure 5: Installation Template Figure 6: DU Mounting Bracket

38 7.1.4 DU Control Panel Installation The DU Control Panel must be mounted within 20 inches of the DU. The placement of the Control Panel is left to the discretion of the installer, but it is recommended that the unit be mounted in as close proximity to the DU as possible. 1. Once the general site for the Control Panel is determined, a small hole is drilled in the instrument panel in the approximate center of the large hole in the template. A screw and fender washer is then used to hold the template, through hole E, in place against the instrument panel. 2. It is now possible to fine tune the position of the template. Once the final position is determined tighten the mounting screw to firmly secure the installation template. 3. Using the template holes as a guide, drill all eight (8) holes B and D and two (2) holes A on either side of the Control Panel cutout using the respective specified sized drill. 4. Connect the holes D with straight-lines and cut-out the mounting hole accordingly. File as required. 5. Countersink the two 4-40 mounting bracket holes A then install the Control Panel Mounting Bracket ( ) directly behind the panel utilizing the 4-40 mounting holes in the top and the bottom of the bracket. 6. Install the Control Panel in the Instrument panel inserting the using the four supplied 4-40 x 3/8 Socket Head Cap Screws ( ) through the Control Panel and the into Control Panel Mounting Bracket. Figure 7: Control Panel

39 7.1.5 DU Connector Definitions P3 P1 Left P4 P2 Right Figure 8: Connector Definition Network Interface Cables There are Three (3) network cables included with each system. They are supplied with flying leads and will require cutting to length and termination at a Cannon connector. A DMC AFM8 type crimper with K578 positioner is required to install the Trident pins in the Cannon connectors. Instructions for terminating these cables are located in Section 12. The cables are: TAB TAB TAB-1 FQU to DU DU to EIU FQU to EIU

40 Figure 9: Typical Network Cable ( xx-TAB-X) Pin Function Pin # CAN A + A CAN A - B CAN B + C CAN B - D RPM LED + (Left Engine)* E RPM LED - (Left Engine)* F OP LED + (Left Engine)* G OP LED - (Left Engine)* H AMP LED + (Left Engine)* J AMP LED - (Left Engine)* K VAC LED + (Left Engine)* L Shield Ground M Right Engine Select (Active Low) N Left Engine Select (Active Low) P Network Reset - R Aircraft Power + S Filtered Aircraft PWR RTN T N/C U Network Reset + V * Single Engine Models Only Figure 10: Network Cables Connector Pin Definition

41 7.1.7 Determine the Firewall Mounting Hole Position Typically the cables will follow the routing of the existing engine sensor wiring which will be removed. For pressurized models be sure to reseal the penetrations appropriately.. Note: For pressurized models see Section 11 for specific installation instructions and penetration locations. Figure 11: EIU & Cable Typical Installation Connect the Network Cables 1. Connect the DU to EIU network cable to the P1 connector on the back of the DU, then run the cable through the airframe to the LEFT EIU and install the supplied sealed connector and ferrite

42 2. Connect the DU to FQU network cable from the P2 connector on the back of the DU, then run the cable through the airframe to P1 on the FQU and install the supplied connector. 3.. Connect the FQU to EIU network cable from the P2 connector on the FQU then run the cable through the airframe to the Right Engine EIU and install the supplied ferrite and sealed connector Connect the Cockpit Cable Note: The AuRACLE CRM 2120 Cockpit Cable is pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion. Figure 13: DU Cockpit Cable ( TAB) Pin Function Pin # Wire Label Power Bus A + A 2-Conductor #1 White Power A Power Bus A - B 2-Conductor #1 White/Blue Power A Lighting Bus C 1-Conductor #1 White Lighting Bus Fuel Data (RS-232 Out) D 2-Conductor #2 White Fuel Data GPS Data (RS-232 IN) E 2-Conductor #3 White GPS Data OAT - F 2-Conductor #2 White/Blue OAT VAC Gnd G 3-Conductor #1 White/Blue PRESSURE VAC Pwr H 3-Conductor #1 White/Orange PRESSURE VAC Signal J 3-Conductor #1 White PRESSURE OAT + K 2-Conductor #2 White OAT Case GND L 1-Conductor #3 Green Case GND Alarm (Sink to GND) M 1-Conductor #2 White Alarm (GND) GPS Data Ret N 2-Conductor #2 White/Blue GPS Data Fuel Data Ret P 2-Conductor #3 White/Blue Fuel Data

43 Pin Function Pin # Wire Label Power Bus B+ R 2-Conductor #4 White Power B Power Bus B- S 2-Conductor #4 White/Blue Power B N/C T-Z Figure 14: Cockpit Cable Connector Pin Definition Install Cockpit Cable WARNING: When wiring connections and securing the cable, be sure wiring does not obstruct the aircraft control movement under the instrument panel Connect the Power WARNING: This system is designed to be connected DIRECTLY to the aircraft MASTER power bus NOT the avionics bus. The AuRACLE system must have power applied and be completely though its power-on sequence and self-tests prior to engine start. The AuRACLE automatically accommodates both 12 and 24-volt electrical systems. 1. Using the 2-Conductor #1 Cable from the P3 connector, connect the Power Bus A+ lead (WHITE) to a separate 5-amp circuit breaker connected to the MASTER power bus. 2. Using the 2-Conductor #1 Cable from the P3 connector, connect the Power Bus A- lead (WHITE/BLUE) to an Electrically Clean Ground. 3. Using the 2-Conductor #4 Cable from the P3 connector, connect the Power Bus B+ lead (WHITE) to a separate 5-amp circuit breaker connected to the MASTER power bus. 4. Using the 2-Conductor #4 Cable from the P3 connector, connect the Power Bus B- lead (WHITE/BLUE) to an Electrically Clean Ground 5. Connect the Case Ground wire (GREEN) to the airframe as near the DU as is possible Connect to the Lighting Bus The AuRACLE automatically adjusts the LCD screen back-lighting based on the monitored Lighting Bus voltage. 1. Using the 1-Conductor #1 Cable from the P3 connector harness, connect the Lighting Bus lead (WHITE) to the Cockpit Lighting Bus Connect the OAT Sensor 1. Remove the existing OAT thermometer. Locate the OAT sensor in the existing OAT location. 2. Attach the sensor using the supplied hardware. 3. Identify the proper wire in the harness

44 4. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 5. Slip the insulating sleeve on the wire. 6. Using the 2-Conductor #2 Cable from the P3 connector, connect the OAT+ lead (WHITE) to the Red? Lead of the OAT sensor 7. Using the 2-Conductor #2 Cable from the P3 connector, connect the OAT- lead (White/Blue) to the White/Blue Lead of the OAT sensor 8. Slide the protective sleeve over the electrical connections and secure in place Connect Alarm The AuRACLE is supplied with an ALARM connection. This is actually an input which will sink (connect) to GROUND when the alarm is activated. The connection can be wired as the ground connection of a status light or audible annunciator. Note: the other end of the device to be activated must be connected to power; the AuRACLE provides a current path to ground not power. This supports WIRED-OR type connections. 1. Connect the 1-Conductor #2 Cable from the P1 connector harness connections labeled ALARM (WHITE) to the device to be actuated (Cockpit Alarm, Master Cautionary Light) ground side. Alarm Connection limitations are as follows: Voltage: 32 Volts Current: 250 ma (at 32V) Connect GPS The AuRACLE will support the following panel mount GPS systems; Garmin GNS430, GNS530, GNS480, Bendix/King KLN89/89B/94, and KLN90. Follow the charts below for your specific model. GNS 430 Hardware Interface The following diagram shows which pins on the respective connectors are used for connecting the GNS-430 Channel 1 to an AuRACLE. Channel 1 is located on the P4001/J4001 of the GPS

45 Note: Even though the Garmin 430 has many serial ports, the AuRACLE must be interfaced to Channel 1. This channel is specified by Garmin to be the channel that can receive fuel data. Fuel should be on pin 57, GPS should be on pin 56, and GND should be connected to chassis ground as there is no Channel 1 ground pin. The following configuration should be selected from the Garmin serial port setup menu. INPUT OUTPUT Shadin-fuel Aviation GNS 530 Hardware Interface The following diagram shows which pins on the respective connectors are used for connecting the GNS-530 Channel 1 to an AuRACLE. Channel 1 is located on the P5001/J5001 of the GPS. AuRACLE DU GNS Fuel 2120 P3 D 56 GPS E RTN P,N Note: Even though the Garmin 530 has many serial ports, the AuRACLE must be interfaced to Channel 1. This channel is specified by Garmin to be the channel that can receive fuel data. Fuel should be on pin 57, GPS should be on pin 56, and GND should be connected to chassis ground as there is no Channel 1 ground pin. The following configuration should be selected from the Garmin serial port setup menu. INPUT Shadin-fuel OUTPUT Aviation GNS 480 Hardware Interface The following diagram shows which pins on the respective connectors are used for connecting the GNS-480 Channel 2 to an AuRACLE. Channel 2 is located on the P1 of the GPS

46 Note: Even though the Garmin 480 has many serial ports, the AuRACLE must be interfaced to Channel 2 or Channel 5. The preferred RS232 channel is 2 on the 480; but Channel 5 may also be used. Channel 5 connections are located on the peripheral I/O connector P5 of the unit. Fuel should be on pin 1, GPS should be on pin 21, and GND should be on pin 41. The following configuration should be selected from the Garmin serial port setup menu. INPUT Shadin-fuel OUTPUT Aviation Bendix/King KLN 89/89B/94 Hardware Interface The following diagram shows which pins on the respective connectors are used for connecting the KLN89/89B/94 to an AuRACLE. KLN 90 Hardware Interface The following diagram shows which pins on the respective connectors are used for connecting the KLN89/89B/94 to an AuRACLE

47 Post Light Requirement The installing A&P shall determine if the existing instrument panel lighting is sufficient to illuminate the legends associated with the pushbutton and the knobs on the AuRACLE Control Unit. If the illumination is insufficient the A&P shall install a post light in a fashion that will properly illuminate these legends and controls

48

49 7.2 Fuel Quantity Unit (FQU) Installation Mount the FQU where space allows either behind the panel or under the floor. Make sure to leave enough room for the cable connectors (about 3 inches) and attach with the #6-32 hardware included in the kit. P3 P2 Right P1 Left P4 Figure 15: Fuel Quantity Unit (FQU) Note: The AuRACLE CRM 2120 FQU Cables are pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion

50 Figure 16: FQU to Fuel Tank Cable ( Tab) Pin Function Pin # Wire Description Wire # Return Tank 1 A Blue/White W1 Tank Sensor 1 B White W1 Safety Gnd 1 C Shield W1 & W2 Return Tank 2 D Blue/White W2 Tank Sensor 2 E White W2 Safety Gnd 2 F Green W5 Return Tank 3 G Blue/White W3 Tank Sensor 3 H White W3 Safety Gnd 3 J Shield W3 &4 Return Tank 4 K Blue/White W4 Tank Sensor 4 L White W4 Safety Gnd 4 M Green W6 Figure 17: FQU to FUEL TANK Connector Pin Definition ( TAB)

51 7.2.1 Install FQU to CO and AMPS Cable Figure 18: FQU to CO and AMPS Cable ( Tab) Pin Function Pin # Wire Description Wire # AMPS + A White W1 N/C B N/C W1 AMPS - C Blue/White W1 Chassis Ground D Shield W1 & W2 CO Tx (RS232) E Red/White W2 Signal Ground F Blue/White W2 CO Rx (RS232) G White W2 Chassis Ground H Green W3 Figure 19: FQU to CO and AMPS Connector Pin Definition ( TAB)

52 7.2.2 Connect CO Detector If the aircraft is equipped with a CO Guardian 452 carbon monoxide detector with an RS232 output, connect it to pins E and G. Once the system is installed and running, go to the SETUP menu, INSTRUMENTS, CO, and select Sensor Present? - Yes. The range is pre-scaled. CO Guardian 452 Remote CO Detector CO Sensor Setup Screen

53 7.3 Engine Interface Unit (EIU) Installation Attach the 6-Cyl Electronics Enclosure P1 J1-2 J1-1 Figure 20: EIU Connector Definitions Note: The AuRACLE EIU should not be mounted with the J1-1 and J1-2 connectors pointing UP. This may compromise the units sealed connectors as fluids may pool. Note: If this installation is in a pressurized aircraft see section 11 for additional instructions. 1. Determine the proper location for mounting the EIU. Be sure that you will have access to the mounting hardware on the cockpit side of the Firewall and that provides access to the connectors for wiring. 2. Drill mounting Holes A at the EIU mounting location using the Installation Template. 3. The EIU should be mounted using #8-32 structural screws and flat washers with nyloc nuts. The spacers ( ) should be installed between the feet of the EIU and the firewall if it is necessary to avoid contact with the strengthening ribs. 4. Insure Mounting screws are tightened snugly. Do not over-tighten

54 The following picture shows the EIU mounted on the Firewall and the Network Cable and Firewall penetration. Figure 21: Typical EIU & Network Cable Installation (Cessna 414A) Install the Network Cables 1. Routing the network cables and terminating them is the most difficult part of the installation. It will depend on the location of the Fuel Quantity Unit (FQU) and the location of the existing engine sensor wire runs out to each nacelle. It will be easiest to run the network cables in the same place that the old sensor wires were run. Each network cable will end up with two (2) ferrite beads installed, one at the DU and the other at the EIU. The ferrites at the EIU s will be installed on-site along with the EIU network cable connector (see attached installation instructions). 2. Start by feeding the cables from the DU location and out to the right engine and to the FQU. The connector that you will install at the FQU will be a standard Cannon type without a ferrite or shrink wrap. The connector at the EIU will have a ferrite bead with shrink wrap and a waterproof connector with shrink wrap

55 7.3.3 Terminate Network Cables - Position ferrite core item 5 on the cable assy. to dimension shown on figure 11 and the shrink tubing, item 6 over to keep the core in place. - Separate the clamp body, the two pressure rings, the sealing grommet, the clamp and the O-ring from the backshells. - Slide the backshell components over the cable. The farthest part from the connector is the clamp, followed by a pressure ring, then the grommet, then the other pressure ring, then the clamp body and then the O-ring as shown on figure 8. Assembly Note: The grommet is a layered design. For our application remove and discard the smallest layer of the grommet. If the grommet resists sliding over the cable, lubricate with isopropyl alcohol. Figure 8 - Remove 1 ¼ in. of the outer jacket, braid and sheathing from one end of cable W1 ( ). - Strip each of the individual wires 0.20 and twist the strands of each. - Preserve individual pair relationships. - Crimp item 2 (socket), part # on stripped wires. Use crimp tool M22520/1-01with locator (Daniels TH 499) set on the GRN position and the dial gage set for 24 awg wire

56 - Place the contact into the locator and insert the wire into the contact as indicated on the locator (turret) label. - Cycle the tool. -Remove and inspect contact. Strands should be visible through the inspection window (see Figure 6). There should be no loose strands (see Figure 7). -Insert wire with crimped sockets into connector plug item 1 ( ) as shown below following the color/pair code in the table. Pair # Pair Color Color of Pair Connector Terminal White of Pair Connector Terminal 1 White paired with Black A B 2 White paired with Brown C D 3 White paired with Red* E F 4 White paired with Orange* G H 5 White paired with Yellow* J K 6 White paired with Green* L U 7 White paired with Blue N P 8 White paired with Violet V R 9 White paired with Gray S T Shield Shield Drain M N/A * Single Engine Systems Only

57 Insure all sockets are fully seated by pulling lightly on the wire in each terminal position. Continuity test Check end to end Continuity of the cable assy. against the table above. Assemble - Slide the O-ring up and over the back of the connector. - Screw the clamp body onto the back of the connector. It should be hand-tight. - Slide the pressure rings and grommet forward into the body. - Screw the cable clamp into the clamp body. The cable clamp will apply pressure to the grommet causing it to seal the backshell to the cable. - Screw down the clamp bar to secure the cable. Note that the bar is reversible, depending on the size of the cable. - Install (1) piece of shrink tubing item 6 (pre cut at 2.5 in long) on each end of the cable assy. and over the backshell and cable. - Position and shrink in place. Note: After shrinking the tubing must be tight around the backshell and the cable and must provide water tight seal at the cable. Figure 11 Figure

58 CONTACT EXTRACTION In the event of a pin being inserted into the wrong terminal position; it may be removed by the procedure below and reinserted

59 Figure 22: DU to EIU Network Cable Pin Function Pin # Wire Color** CAN A + A Black CAN A - B White (A) CAN B + C Brown CAN B - D White (C) RPM LED + (Left Engine)* E Red RPM LED - (Left Engine)* F White (E) OP LED + (Left Engine)* G Orange OP LED - (Left Engine)* H White (G) AMP LED + (Left Engine)* J Yellow AMP LED - (Left Engine)* K White (J) VAC LED + (Left Engine)* L Green Shield Ground M Shield Right Engine Select (Active Low) N Blue Left Engine Select (Active Low) P White (N) Network Reset - R White (V) Aircraft Power + S Gray Filtered Aircraft PWR RTN T White (S) N/C U White (L) Network Reset + V Violet * Single Engine Models Only ** Letters in parenthesis represent the colored wire that the white wire is paired with. Figure 23: Network Cable Connector Pin Definition

60 7.4 Sensor Installation EIU Sensor Interface Cable J1-2 Note: The AuRACLE EIU Sensor Interface Cable J1-2, 6-Cylinder cable is pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion. DO NOT attempt to remove or add additional wire connections to the connector. This will compromise the integrity of the connector and will void your warranty preventing legal installation in certificated aircraft as the integrity of the connector seal can no longer be guaranteed. Note: This connector is keyed; insure you are inserting it in the proper position and in the proper orientation. Failure to perform this insertion properly will result in damage to the EIU. Figure 24: EIU J1-2 Sensor Cable Pin Function Pin # Wire Label EGT Cyl #6 + L-1 Type K #1 Yellow EGT 6 (Yellow) EGT Cyl #6 - (Red) L-2 Type K #1 Red EGT 6 NC or TIT2 (Yellow) L-3 Insert Sealing Plug Chassis GND M-1 Single Cond. #1 Green GND Chassis GND M-2 Single Cond. #1 Green GND NC or TIT2 (Red) M-3 Insert Sealing Plug

61 Pin Function Pin # Wire Label TIT + (Yellow) N-1 Type K #2 Yellow TIT TIT - (Red) N-2 Type K #2 Red TIT OT + (Yellow) N-3 Type K #3 Yellow OT CT or IAT (Red) P-1 Type K #4 Red CT CT or IAT + (Yellow) P-2 Type K #4 Yellow CT OT (Red) P-3 Type K #3 Red OT CHT Cyl #1 + (White) R-1 Type J #1 White CHT 1 NC or FF2 (-) R-2 Insert Sealing Plug NC or FF2 (+) R-3 Insert Sealing Plug CHT Cyl #2 - (Red) S-1 Type J #2 Red CHT 2 CHT Cyl #2 + (White) S-2 Type J #2 White CHT 2 CHT Cyl #1 - (Red) S-3 Type J #1 Red CHT 1 CHT Cyl #3 + (White) T-1 Type J #3 White CHT 3 CHT Cyl #3 - (Red) T-2 Type J #3 Red CHT 3 CHT Cyl #4 + (White) T-3 Type J #4 White CHT 4 CHT Cyl #5 - (Red) W-1 Type J #5 Red CHT 5 CHT Cyl #5 + (White) W-2 Type J #5 White CHT 5 CHT Cyl #4 - (Red) W-3 Type J #4 Red CHT 4 CHT Cyl #6 + (White) X-1 Type J #6 White CHT 6 CHT Cyl #6 - (Red) X-2 Type J #6 Red CHT 6 CDT + (Yellow) X-3 TAB-1 Insert Sealing Plug CDT TAB-2 Type K #5 Yellow TAB-3 Type K #5 Yellow NC or AMP2 (-) Y-1 Insert Sealing Plug NC or AMP2 (+) Y-2 Insert Sealing Plug CDT - (Red) Y-3 TAB-1 Sealing Plug CDT TAB-2 Type K #5 Red TAB-3 Type K #5 Red Figure 25: EIU Sensor Interface Cable J1-2, Connector Pin Definition EIU Sensor Interface Cable J1-1 Note: The AuRACLE EIU Sensor Interface Cable J1-1, 6-Cylinder cable is pre-manufactured for you with labeled flying leads for each of the respective connections. Modifications for length can be made at the installer s discretion. DO NOT attempt to remove or add additional wire connections to the connector. This will compromise the integrity of the connector and will void your warranty preventing legal installation in certificated aircraft as the integrity of the connector seal can no longer be guaranteed. Note: This connector is keyed; insure you are inserting it in the proper position and in the proper orientation. Failure to perform this insertion properly will result in damage to the EIU

62 Figure 26: EIU J1-1 Sensor Cable Pin Function Pin # Wire Label RPM GND A-1 3-Conductor #1 White/Blue RPM AMP - A-2 2-Conductor #1 White/Blue AMP AMP + A-3 2-Conductor #1 White AMP RPM Signal B-1 3-Conductor #1 White RPM RPM Power B-2 3-Conductor #1 White/Orange RPM FF GND B-3 3-Conductor #2 White/Blue FF FF Signal C-1 3-Conductor #2 White FF FF Power C-2 3-Conductor #2 White/Orange FF OP GND C-3 3-Conductor #3 White/Blue OP OP Signal D-1 3-Conductor #3 White OP OP Power D-2 3-Conductor #3 White/Orange OP MAP GND D-3 3-Conductor #4 White/Blue MAP MAP Signal E-1 3-Conductor #4 White MAP MAP Power E-2 3-Conductor #4 White/Orange MAP VAC GND E-3 3-Conductor #5 White/Blue VAC VAC Signal F-1 3-Conductor #5 White VAC VAC Power F-2 3-Conductor #5 White/Orange VAC FP GND F-3 3-Conductor #6 White/Blue FP FP Signal G-1 3-Conductor #6 White FP FP Power G-2 3-Conductor #6 White/Orange FP EGT Cyl #1 + (Yellow) G-3 Type K #1 Yellow EGT

63 Pin Function Pin # Wire Label EGT Cyl #2 - (Red) H-1 Type K #2 Red EGT 2 EGT Cyl #2 + (Yellow) H-2 Type K #2 Yellow EGT 2 EGT Cyl #1 - (Red) H-3 Type K #1 Red EGT 1 EGT Cyl #3 + (Yellow) J-1 Type K #3 Yellow EGT 3 EGT Cyl #3 - (Red) J-2 Type K #3 Red EGT 3 EGT Cyl #4 + (Yellow) J-3 Type K #4 Yellow EGT 4 EGT Cyl #5 - (Red) K-1 Type K #5 Red EGT 5 EGT Cyl #5 + (Yellow) K-2 Type K #5 Yellow EGT 5 EGT Cyl #4 - (Red) K-3 Type K #4 Red EGT 4 Figure 27: EIU Sensor Interface Cable J1-1 Connector Pin Definitions Sensor Wiring General Recommendations ALL sensor wiring should be routed away from high temperature areas ALL sensor wiring should NOT be routed with ignition, alternator, or other high-current carrying connections. When the installation is complete, all wires should be secured and carefully checked for interference, chaffing, etc. Use best practice wiring techniques. Note: If any sensors are not installed. The associated wire may be cut short. In any case, insulate individual conductors so that they do not short to each other or anything else Thermocouple Wiring General Recommendations When cutting the pair of leads to the proper length to connect to the sensors, leave enough slack in the wiring so that sensors may be interchanged to an adjacent cylinder if necessary for trouble-shooting and servicing. Thermocouple wire length is not critical and should be trimmed to any length as required for a clean installation. The Temperature sensor must be wired with the correct polarity. The temperature sensor connects to its temperature indicator with thermocouple wire supplied. Strip the wires as shown below observing color-coding. Terminate each wire with a crimp-on ring terminal. The ring terminals may be crimped with a service-type tool, however AMP part number crimp tool is recommended. Verify the quality of each crimp with a sharp tug on the wire. The terminal should be impossible to pull off when crimped correctly. Place a ¼ x 4-inch sleeve over each pair of wires in the wiring. Connect the wire ring lug to the sensor ring lug using the supplied number 4 screws and nuts, placing the star washer between the ring lugs, not against the nut. Slide the protective sleeve over the joint and secure with tie-wraps

64 Note: On both Type-J and Type-K thermocouples one wire of the pair is magnetic and the other is not. One can always determine how to connect wires with a small magnet. Always connect magnetic wire to magnetic wire and connect non-magnetic wire to non-magnetic wire. WARNING: Do not extend thermocouple wire with copper wire Pressure Sensor Mounting General Recommendations The AuRACLE pressure senders are all the same sensor type, with different pressure ranges. Figure 28: Pressure Sensor Figure 29: Pressure Sensor Remote Mounting WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5)

65 Figure 30: Typical Sensor Bracket Mounting ( )

66 7.4.6 Install EGT Sensor Figure 31: EGT Sensor 1. Locate the EGT sensors not less than 2 or more than 6 below the exhaust stack attachment flange. 3 to 4 is optimum. CAUTION: All sensors must be mounted an equal distance from the exhaust flanges. On curved exhaust stacks, assume the sensor tip is on the stack centerline for determining the distance to the exhaust flange. 2. Carefully center punch the sensor hole locations such that the portions of the sensors external to the exhaust pipes will not interfere with any parts of the engine or cowling. Drill holes with a #33 drill. 3. Carefully insert the sensors and clamp snugly with screwdriver. 4. Identify the proper wire in the harness for a single EGT sensor. 5. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 6. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 7. Slip the protective sleeve over the wire. 8. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 9. Slide the protective sleeve over the electrical connections and secure in place. 10. Repeat seeps 4 through 9 for each EGT Sensor

67 7.4.7 Install CHT Sensors Figure 32: CHT Sensor 1. Find the Cylinder head temperature mounting hole for all cylinders. 2. Apply a small amount of anti-seize to the sensor threads then screw the sensor into this hole in each cylinder. 3. Identify the proper wire in the harness for a single CHT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 6. Slip the protective sleeve over the wire. The sensor wires are now connected to the EIU harness. Be sure to connect wires WHITE to WHITE and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the White wire of a Type J thermocouple is magnetic and the Red is not. Always connect magnetic to magnetic and non-magnetic to non-magnetic. Note: There is a possibility that an older color code is used on the CHT sensors this will be Yellow and Black. In this case connect Black to White (both magnetic) and Yellow to Red (both nonmagnetic). 7. Slide the protective sleeve over the electrical connections and secure in place. 8. Repeat seeps 4 through 9 for each CHT Sensor

68 7.4.8 Install TIT Sensor(s) (if req.) Figure 33: TIT Sensor 1. Carefully center punch the sensor hole locations such that the portions of the sensors external to the exhaust pipes will not interfere with any parts of the engine or cowling. Drill holes with a #33 drill. 2. Carefully insert sensor and clamp snugly with screwdriver. 3. Identify the proper wire in the harness for the TIT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 6. Slip the protective sleeve over the wire. 7. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 8. Slide the protective sleeve over the electrical connections and secure in place

69 7.4.9 Carburetor Temperature Sensor (if req.) Figure 34: Carburetor Temperature Sensor 1. Carefully insert sensor and tighten snugly. 2. Identify the proper wire in the harness for the CT sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 5. Slip the protective sleeve over the wire. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 6. Slide the protective sleeve over the electrical connections and secure in place Install Induction Temperature Sensor (if req.) The Induction Air Temperature sensor is installed just after the inter-cooler. The sensor is installed similarly to an EGT sensor

70 Figure 35: IAT Sensor 1. Carefully center punch the sensor hole location such that the portions of the sensor so it will not interfere with any parts of the engine or cowling. Drill hole with a #33 drill. 2. Carefully insert sensor and clamp snugly with screwdriver. 3. Identify the proper wire in the harness for the IAT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 6. Slip the protective sleeve on the wire. 7. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 8. Slide the protective sleeve over the electrical connections and secure in place Install Compressor Discharge Temperature Sensor (if req.) The Compressor Discharge Temperature sensor, (CDT), is installed just before the inter-cooler. The sensor is installed similarly to an EGT sensor

71 Figure 36: CDT Sensor 1. Carefully center punch the sensor hole location such that the portions of the sensor so it will not interfere with any parts of the engine or cowling. Drill hole with a #33 drill. 2. Carefully insert sensor and clamp snugly with screwdriver. 3. Identify the proper wire in the harness for the CDT sensor. 4. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 5. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 6. Slip the protective sleeve over the wire. 7. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut. If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 8. Slide the protective sleeve over the electrical connections and secure in place

72 Install Oil Temperature Sensor Figure 37: Typical Oil Temperature Sensor 1. Carefully install the oil temperature sensor into the appropriate (OEM) location. Tighten snugly to insure there will be no leaks. 2. Identify the proper wire in the harness for the OT sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires, and crimp on Ring connectors. 5. Slip the protective sleeve over the wire. The sensor wires are now connected to the EIU harness. Be sure to connect wires YELLOW to YELLOW and RED to RED with 6-32 Screws, Nuts and Toothed Washers. The toothed washer goes BETWEEN the ring terminals, not under the nut.. If there is any doubt about the color of the wire; the Red wire of a Type K thermocouple is magnetic and the Yellow is not. Connect Magnetic to Magnetic and non-magnetic to non-magnetic. 6. Slide the protective sleeve over the electrical connections and secure in place

73 Install Oil Pressure Sensor Figure 38: Oil Pressure Sensor 1. Mount the Oil Pressure sensor in accordance with the general recommendations above (see Section 7.4.5). 2. Identify the proper wire in the harness for the OP sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeves over the wires. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE WHITE/ORANGE WHITE WHITE WHITE/BLUE WHITE/BLUE 7. Slip protective sleeve over splices and secure in place. WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5)

74 Install Manifold Absolute Pressure (MAP) Sensor Figure 39: Manifold Absolute Pressure Sensor 1. Mount the Manifold Absolute Pressure sensor in accordance with the general recommendations above (see Section 7.4.5). 2. Identify the proper wire in the harness for the MAP sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeves over the wires. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE WHITE/ORANGE WHITE WHITE WHITE/BLUE WHITE/BLUE 7. Slip protective sleeve over splices and secure in place. WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5) Install Instrument Air Pressure/Vacuum Sensor WARNING: The Vacuum or Instrument Pressure system should be properly checked for leaks

75 and verified per the OEM requirements after the installation of the AuRACLE sensor. Insure the sensor is installed in the regulated portion of the instrument pneumatic system. Note: In a Vacuum System use sensor , in a Pressure System use sensor Figure 40: Instrument Air Pressure Sensor 1. Mount the Instrument Air Pressure/Vacuum sensor in accordance with the general recommendations above (see Section 7.4.5). 2. Identify the proper wire in the harness for the IP/VAC sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeves over the wires. 6. Wire using butt splices as listed: Sensor Harness WHITE/ORANGE WHITE/ORANGE WHITE WHITE WHITE/BLUE WHITE/BLUE 7. Slip protective sleeve over the splices and secure in place. WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5)

76 Install Fuel Pressure Sensor Figure 41: Fuel Pressure Sensor 1. Mount the Fuel Pressure (FP) sensor between the engine driven fuel pump and the servo/carburetor in accordance with the general recommendations above (see Section 7.4.5). 2. Identify the proper wire in the harness for the FP sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor Wires. 5. Slip protective sleeve over the wire. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE WHITE/ORANGE WHITE WHITE WHITE/BLUE WHITE/BLUE 7. Slip protective sleeve over the splices and secure in place. WARNING: Never connect a pressure sensor directly to the engine. See recommended mounting scheme (section 7.3.5)

77 Install RPM Sensor Note: If your aircraft utilizes an electronic ignition system, contact the factory for additional assistance Solid-State Magneto Pick-up (Slick or Bendix Magnetos) Figure 42: Solid-State RPM Sensor 1. Carefully screw the sensor into the front inspection port (closest to the accessory case) on a magneto. Tighten snugly to insure there will be no leaks. 2. Identify the proper wire in the harness for the RPM sensor. 3. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 4. Cut the extension wires to length. Strip the harness wires and the sensor wires. 5. Slip protective sleeves over the wires. 6. Wire connections using butt splices as listed: Sensor Harness WHITE/ORANGE WHITE/ORANGE WHITE WHITE WHITE/BLUE WHITE/BLUE 7. Slip protective sleeve over the splices and secure in place. 8. If the mechanical tachometer is being removed: remove the mechanical tachometer cable; install the provided tachometer cable cap on the engine fitting. Note: Install the sensor in the inspection port closest to the engine block

78 Install Current Shunts There are three current shunts included with the One in each of the alternator circuits as shown in Figure 44 below in a load configuration. They connect to their respective EIU s. The third goes in the battery circuit as shown in Figure 43 below. This shunt connects to the FQU AMPS input wires on pin A (+) and C (-). The following Wiring diagram shows schematically how to connect the Current Shunts in the two configurations. CAUTION: The Current Shunt must be installed such that it is at the battery voltage whenever the AuRACLE is in operation. That is, it must not be switched off the battery while the AuRACLE is in operation. Failure to comply could result in erroneous current readings. Figure 44: Current Shunt Installation Schematic (Charge Type)

79 Figure 45: Current Shunt Installation Schematic (Load Type) 1. Remove the existing current shunt. 2. Connect the Shunt as shown above; being careful to preserve the original configuration 3. Mount the provided current shunt with the 8-32 screws, locking washers, and nuts provided. 4. Identify the proper wire in the harness for the Shunt. 5. AVOID CONTACT OF LEADS WITH CYLINDER HEADS OR EXHAUST PIPES. DO NOT ROUTE WITH THE IGNITION HARNESS. 6. Cut the extension wires to length. Strip the harness wires and crimp on Ring connectors. 7. Connect the WHITE conductor of the wire Labeled Amps to the Battery/Alternator side of the Current Shunt. 8. Connect the WHITE/BLUE conductor of the wire Labeled Amps to the Bus side of the Current Shunt. WARNING: There should be fuses in both signal lines from the current shunt to the AuRACLE. If no such fuses are present Ultra Electronics - Flightline Systems recommends ½ Amp fast acting fuses be installed

80 Install Fuel Flow Sensor The inlet and outlet ports in the fuel flow transducer have ¼ NPT threads. Use only ¼ NPT hose or pipe fittings to match. When assembling fittings into the inlet and outlet ports DO NOT EXCEED a torque of 180 inch lbs, or screw the fittings in more than 2 full turns past hand tight WHICHEVER HAPPENS FIRST. If possible, secure the transducer using two 0.25-inch bolt holes through the body of the transducer to the structure of the aircraft. This will provide the most secure installation. Please be aware of any heat sources the transducer might be subjected to during operation. If the installation prevents you from bolting the transducer as mentioned above, you may suspend the transducer within an existing grouping of fuel lines as long as they are supported with Adel clamps or something similar. The Floscan flowmeter is designed to allow fuel to continue to flow with minimal pressure drop if the rotor becomes seized. If the rotor becomes seized, the displayed Fuel Flow on the AuRACLE will drop off dramatically with little or no recognizable decrease in engine power. Additionally, you may witness a drop in the monitored fuel pressure if installed, provided the fuel flow sensor is located on the METERED side rather than the UN-METERED side. Once the Fuel Flow transducer installation is completed, an engine run-up should be performed verifying the minimum Fuel Flow based on the aircraft POH. Post-installation Calibration is necessary only in the programming of the AuRACLE with respect to the transducer K-Factor. This is documented on the tag that is attached to the sensor and should be recorded in this manual for use later. To determine the K-Factor, refer to the tag attached to the sensor (KEEP THIS TAG!). Note the number in Fig 38 below. The K-Factor for this particular sensor is (note the added 0 ) and you would enter this in the K field in the SETUP MENU. Figure 46: Fuel Flow Sensor

81 WARNING: Use only aircraft Fuel Lube or equivalent on the NPT fittings. 5-inch hose minimum UP 5-inch hose minimum TO ENGINE Approved Fire Sleeve FROM FUEL TANK Figure 47: Fuel Flow Sensor Installation WARNING: Never use Teflon tape in an aircraft fuel system. WARNING: Never connect a fuel flow sensor directly to the engine. WARNING: Always cover the fuel flow sensor with an approved fire sleeve. A screen or filter should be installed upstream of the flow sensor to screen out debris which could affect rotor movement or settle in the V-bearings. Mount the fuel flow sensor in a position so the three wire leads are pointed straight up. Use only smooth radius curves in the fuel line and place the sensor with 5 of straight line before and after. The sensor should be mounted according to the fuel metering device manufacturer s recommendations. Based on the aircraft fuel system, one of the following sensor locations should be chosen: Previous installations have yielded exceptional results when the following conditions have been met: 1. The sensor is mounted in a stationary location in line between the electric boost pump and the engine driven pump. 2. The sensor is mounted in a stationary location in line between the fuel injection servo and the distribution block. 3. The sensor is mounted in a stationary location inline between the Engine driven pump and the Carburetor

82 Previous installations have yielded excellent results when the following conditions have been met: The sensor should be mounted such that he fuel will travel uphill by one to two inches after leaving the transducer. The sensor wires will then be connected to the respective J1-1 EIU harness. The shield need not be connected. Sensor Harness RED - WHITE/ORANGE BLACK - WHITE/BLUE WHITE - WHITE 7.5 Compute the Total Weight and Moment Changes Compute the change in the aircraft weight and total moment using the methods detailed in AC B chapter 10. Record the results in the POH. Nominal weights are provided for convenience only. The installer must weigh all components installed and removed. Item Weight (Lbs) AuRACLE CRM 2120 DU 3.8 AuRACLE CRM 2120 EIU 1.4 Fuel Quantity Unit 1.5 EGT Thermocouples (6) 0.1 CHT Thermocouples (6) 0.1 OT Thermocouple 0.2 TIT Thermocouple 0.2 IAT Thermocouple 0.2 CDT Thermocouple 0.2 CT Thermocouple 0.2 OAT Thermocouple 0.2 RPM Sensor 0.1 MAP Sensor 0.2 OP Sensor 0.2 Inst. Press. Sensor 0.2 VAC Sensor 0.2 FP Sensor 0.2 Transducer Mounting Bracket 0.6 FF Sensor 0.2 Current Shunt 0.1 Circuit Prot. Device Negligible Wire and Cable 2.0 Figure 48: Nominal AuRACLE Component Weights

83 7.6 Load Operational Parameters The Operational Parameter file (OP file) will be supplied by Ultra Technical Support via . This file is based on data from the Auracle Installation Questionnaire that was sent upon system order as well as engine data in the instrument marking pages from the aircraft s POH which should have also been sent along with the questionnaire. To download this file from your Instructions for downloading AuRACLE operating parameter (OP) file: 1. Copy the attached file, OP csv, to your USB drive. CAUTION! DO NOT OPEN THIS FILE! Opening the file will corrupt it and we will have to send you a new file. 2. Power up the AuRACLE. 3. From the BLUE screen you will be prompted to insert the USB drive. 4. Once the file has successfully loaded, a GREEN screen will prompt you to remove the USB drive and recycle power to the system. 5. Once you have recycled power, acknowledge the Fuel Entry screen. 6. Go to the SETUP utility and set the date and time. 7. If you have any questions regarding this procedure, be sure to contact our Technical Support department at Calibrate Fuel Level NOTE: Prior to calibrating fuel level indicators, be sure that tanks are completely empty. 1. Power up the AuRACLE 2. Navigate to SETUP and press the white FUNCTION button 3. Navigate to the Instruments button and press the black knob 4. Navigate to the FQ button and press the black knob

84 5. Navigate to the Left Main Calibrate and press enter 6. Add the UNUSEABLE amount of fuel to the tank being calibrated 7. Navigate to the E amount box and press the black knob ONCE

85 8. Add fuel equal to 1/4 of a tank 9. Navigate to the 1/4 amount box and press the black button ONCE 10. If you add more than the value for ¼, that numerical value can be entered by highlighting the ¼ field and rotating the black knob until the amount entered is displayed. Then press the black knob ONCE. 11. Add fuel equal to ½ full. Navigate to the 1/2 amount box and repeat the process in steps 9 and Add fuel equal to 3/4 full. Navigate to the 3/4 amount box and repeat the process in steps 9 and Add fuel equal to a FULL tank. Navigate to the F amount box and repeat the process in steps 9 and

86 14. Navigate to the Save and Return box and press the black knob ONCE 15. Repeat the above procedure for each of the remaining fuel tanks. 16. When the process is complete press the black knob to Save and Return to the MAIN screen. 17. Insert the USB drive and wait for the download to complete (USB indicator turns GREEN). 18. The file, OP csv will be downloaded to your USB drive. Send this downloaded file via to Ultra Electronics Flightline Systems Technical Support for formatting. You will receive an updated Operational Parameter file (OP csv) from Ultra to load into your system. To do this, copy the file (OP csv) to your USB drive. Power up the system and acknowledge the fuel entry screen. Then insert the USB drive and wait for the USB status indicator to turn GREEN. Remove the drive and recycle power to the system. Your Fuel Levels are now set. NOTE: The system is not considered Calibrated until this step (18) is completed and the updated file from Ultra is returned and loaded into the system

87 8 Aircraft Configuration Verification Once the Operational Parameter file has been downloaded to the AuRACLE, it is the responsibility of the installation technician to verify the AuRACLE is configured properly against the appropriate Instrument Marking Report. The Pilot s Guide will guide you through the SETUP page and sub-menus. You can use these procedures to make any required changes as well as to verify settings. The scales, caution limits and warning limits must be verified for every instrument. Failure to do so could present improper readings. WARNING: The scales, caution limits and warning limits must be verified for every instrument. Failure to do so could potentially damage the engine or put the pilot and occupants in a potentially dangerous situation. Until the configuration is confirmed and the Box and Signature line below checked, the installation cannot be signed off as Airworthy. Please contact Ultra Electronics - Flightline Systems at with any questions. AuRACLE Configuration Confirmed: NO YES Confirmed By: (Print Name) (Signature)

88 9 Operation Verification After completing the installation of the AuRACLE the Installer must verify its basic operation. The following procedure will verify the basic operation of the device Instructions If a sensor is not present in the current installation fill space with an N/A. Fill in an approximate number for a referenced value on this form. If multiple values are referenced, EGT for example, record an eyeball average on this form. Fill in all other values with a check mark. Test Pilot Name: Date of test: Tail Number: Ambient Temperature: Barometric Pressure: Field Elevation: 1. With the engine cold and tanks full apply Power to the AuRACLE i. Three Screens appear one after the other (red, green, blue). ii. Ultra Electronics Splash screen appears showing the proper tail number. iii. Fuel Load screen appears b. Enter Fuel tanks full on the AuRACLE. Verify fuel load is as programmed. c. Examine FUEL LEVEL readings. They should read current fuel levels. d. Examine Temperatures all should be close to ambient temperature i. All EGT ii. All CHT iii. TIT iv. OT v. CDT vi. CT/IAT vii. OAT e. Examine MAP reading. It should be the Barometer corrected to elevation. f. Examine Volts reading. It should read approximately battery voltage. g. Examine Amps reading. It should show a small discharge. h. Examine Oil P Reading. It should be approximately zero

89 i. Examine VAC/IP reading. It should be approximately zero. j. Examine Fuel P Reading. It should be approximately zero. k. Turn on Cockpit lights very dim. Insure Display dim s. 2. Point the aircraft in the four cardinal compass directions Insure there is no interaction between the AuRACLE and the compass. 3. Set AuRACLE to MAIN mode and Start Engine and Idle a. Insure Oil P rises to normal pressure in a reasonable time. b. Examine Amps reading. It should show a charge c. RPM should be reading idle speed. d. MAP should be reading idle speed MAP value e. FF should be showing an idle FF Value f. EGTs should all be reading normal EGT readings g. TIT Should be reading close to EGTs h. CHTs should rise slowly and stabilize i. Oil T should rise slowly and stabilize j. CT/IAT should rise slowly and stabilize k. CDT should rise slowly and stabilize l. Volts should read a normal operating voltage m. Amps 1 & 2 should read in the normal range n. Amps 3 should decrease and stay around zero o. Vac/IP should read in the normal range p. Fuel P should read in the normal range q. OAT should not change from ambient r. Fuel Level should read current levels s. Fuel load decreasing slowly 4. Perform the following EMC/EMI tests. This test must be conducted outside, with the Engine running. Correct any issues that are discovered in these tests. Note: The equipment list below is provided as an example of a typical installation. Test all electronic equipment in a given installation (record results of equipment not listed in the comments section of this document). Use blank spaces to record test on aircraft specific equipment (Source and Victim). Source Equipment Monitor Equipment (Victim) Remarks Source Function Victim Equip Function Audio Visual Equip VHF 1 Transmit AuRACLE On VHF 1 Transmit AuRACLE On

90 Source Equipment Monitor Equipment (Victim) Remarks Source Function Victim Equip Function Audio Visual Equip VHF 1 Transmit AuRACLE On VHF 1 Transmit AuRACLE On VHF 2 Transmit AuRACLE On VHF 2 Transmit AuRACLE On VHF 2 Transmit AuRACLE On VHF 2 Transmit AuRACLE On Autopilot Engage AuRACLE On Strobe Lights On AuRACLE On VOR/ILS Tune Local AuRACLE On DME Tune Local AuRACLE On ADF Tune Local AuRACLE On GPS On AuRACLE On Transponder On AuRACLE On All Lights On AuRACLE On AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive AuRACLE On VHF 2 Receive AuRACLE On VHF 2 Receive AuRACLE On VHF 2 Receive AuRACLE On VHF 2 Receive AuRACLE On Autopilot Engage AuRACLE On Strobe Lights On

91 Source Equipment Monitor Equipment (Victim) Remarks Source Function Victim Equip Function Audio Visual Equip AuRACLE On VOR/ILS Tune Local AuRACLE On DME Tune Local AuRACLE On ADF Tune Local AuRACLE On GPS On AuRACLE On Transponder On AuRACLE On All Lights On AuRACLE On VHF 1 Receive AuRACLE On VHF 1 Receive With the engine at a normal cruise power setting apply an expected Night IFR equipment load (Maximum number of equipment expected to be operating) on the electrical system. (See AC B, Chapter 11) a. Is the electrical system is able to supply this load (ammeter reading does not change) 6. Take a test flight, staying in the pattern until the Pilot In Command is comfortable with the operation of the AuRACLE. a. Did the readings appear proper and steady at high power settings b. Is the display clear and readable in various aircraft-sun orientations 7. If the aircraft is GPS equipped, verify (by calculation) that the fuel remaining at some preprogrammed waypoint is reasonable. 8. Land aircraft a. Top off tanks. Verify fuel remaining is correct If any of the above tests fail troubleshoot the circuit. If assistance is required contact Ultra Electronics - Flightline Systems. Signature:

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93 10 Instructions for Continued Airworthiness (ICA) If the aircraft has 0-30 Ohm fuel level sensors, the FQU will require re-calibration if it (FQU) is replaced for any reason. Otherwise there are no field adjustments and or calibration requirements for the AuRACLE Engine Management System once installed properly, configured using the supplied Ultra Electronics - Flightline Systems encrypted data file and the installation inspected and signed-off by the respective authority. ICA is not required. Maintenance of nonfunctioning or malfunctioning components is limited to removal and replacement of Ultra Electronics - Flightline Systems factory supplied new or repaired components as described by these installation instructions

94 11 Pressurized Aircraft 11.1 Penetration Location Locate Cable penetration in the general locations shown; keeping the penetration at least 1 away from strength members. Assure that there are no interfering items on the other side of the pressure bulkhead. For alternate locations, contact Ultra Electronics - Flightline Systems or an FAA DER for approval. Figure 49: Network Cable Penetration Location Cessna P

95 Figure 50: Network Cable Penetration Location Piper PA

96 11.2 Installation Excerpt from AC A